🔧 Explorer - Rear Brake Pads & Rotor Replacement

You’ll remove the rear wheels, take off the rear brake calipers and brackets, replace the rotors, then install new pads and reassemble with correct torque. On your Explorer, the key “gotcha” is the parking brake system—some rear calipers use an Electronic Parking Brake (EPB) motor, which must be put in service mode before you push the pistons back.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• ⚠️ Support the Explorer with jack stands on solid ground; never work under a vehicle held only by a jack.
• ⚠️ Brake dust is harmful—wear a dust mask and use brake cleaner, not compressed air.
• ⚠️ If your rear calipers have an EPB motor (electrical connector on the caliper), put EPB into service/maintenance mode before retracting pistons.
• ⚠️ Do not let a caliper hang by the brake hose; support it with a bungee cord.
• 🔋 Battery disconnect is usually not required, but keep the ignition OFF and keep your key away so the EPB can’t activate unexpectedly.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• 21mm socket
• Breaker bar (1/2")
• Torque wrench (20–250 Nm range)
• 13mm socket
• 15mm socket
• 18mm socket
• Ratchet (3/8")
• Ratchet (1/2")
• Flathead screwdriver
• Pry bar (small)
• Wire brush
• Rubber mallet
• C-clamp brake compressor
• Brake caliper piston wind-back tool (specialty)
• OBD2 scan tool with Ford EPB service mode (specialty)
• Bungee cord
• Nitrile gloves
• Safety glasses
• Dust mask

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Replace in pairs - Qty: 2
• Rear brake hardware kit (clips/shims) - Qty: 1
• Brake caliper slide pin boots (if torn) - Qty: 1
• Brake parts cleaner - Qty: 1
• Brake lubricant (silicone or synthetic) - Qty: 1
• DOT 3 brake fluid - Qty: 1 quart

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📋 Before You Begin

• Park on level ground, steering straight, and place wheel chocks at the front wheels.
• Make sure the EPB is released.
• Open the hood and check the brake fluid reservoir level; if it’s near “MAX,” siphon a little out so it won’t overflow when you retract pistons.
• If your rear calipers have an EPB motor (electrical connector on caliper), connect your OBD2 scan tool with Ford EPB service mode and command EPB Maintenance/Service Mode before you start.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the parking brake system in the correct state

• If your rear caliper has an electric motor with a wiring connector, use an OBD2 scan tool with Ford EPB service mode (specialty) to activate EPB Service/Maintenance Mode and fully retract the motors.
• If your rear caliper has a cable/lever (no motor), ensure the EPB is fully released and do not touch the EPB switch during the job.
• Key off to prevent EPB surprises.

Step 2: Loosen lug nuts and raise the rear

• Use a 21mm socket and breaker bar (1/2") to loosen the rear lug nuts 1/2 turn.
• Use a floor jack (rated 3-ton minimum) to lift the rear and set the Explorer on jack stands (rated 3-ton minimum).
• Remove the wheels using the 21mm socket.

Step 3: Remove the rear caliper (do not stretch the hose)

• Turn the steering wheel is not needed; you’ll work straight-on at the rear.
• Use a flathead screwdriver to gently pry the caliper outward a few millimeters (creates space).
• Remove the caliper slide pin bolts using a 13mm socket and ratchet (3/8").
• Lift the caliper off the bracket and hang it with a bungee cord.
• Torque spec (reassembly): Torque to 35 Nm (26 ft-lbs)

Step 4: Remove brake pads and inspect slide pins

• Pull the inner and outer pads out by hand; use a flathead screwdriver if they’re stuck.
• Pull the slide pins out (one at a time) and wipe them clean.
• Apply a thin coat of brake lubricant (silicone or synthetic) to the smooth part of the pins (not the threads), then reinstall.
• Sticking pins cause uneven pad wear.

Step 5: Remove the caliper bracket

• Use an 18mm socket and ratchet (1/2") to remove the caliper bracket bolts.
• Remove the bracket and set it aside.
• Torque spec (reassembly): Torque to 150 Nm (111 ft-lbs)

Step 6: Remove the old rotor

• If the rotor is rust-stuck, tap the rotor hat with a rubber mallet to break it free.
• If there is a rotor retaining screw, remove it with a flathead screwdriver (press hard to avoid stripping).
• Clean the hub face with a wire brush so the new rotor sits flat.

Step 7: Install the new rotor

• Spray the new rotor with brake parts cleaner to remove protective oil.
• Install the rotor onto the hub.
• If equipped with a retaining screw, reinstall and snug it with a flathead screwdriver.

Step 8: Reinstall the caliper bracket and hardware clips

• Install new hardware clips from the rear brake hardware kit onto the bracket.
• Apply a very thin film of brake lubricant (silicone or synthetic) where the pad “ears” slide on the clips.
• Reinstall the bracket and tighten bolts using an 18mm socket and torque wrench.
• Torque to 150 Nm (111 ft-lbs)

Step 9: Retract the caliper piston (this depends on EPB type)

• If you have EPB motor calipers and already set service mode, use a C-clamp brake compressor to slowly press the piston straight back in.
• If you have cable/lever calipers, use a brake caliper piston wind-back tool (specialty) to rotate-and-push the piston in (this tool presses while turning).
• Watch the brake fluid reservoir while compressing; stop if it starts to overflow.
• Go slow to avoid seal damage.

Step 10: Install new pads and reinstall the caliper

• Install the new inner and outer pads into the bracket by hand.
• Place the caliper over the pads.
• Install the slide pin bolts using a 13mm socket and torque wrench.
• Torque to 35 Nm (26 ft-lbs)

Step 11: Reinstall wheels and torque lug nuts

• Install wheels and hand-thread lug nuts.
• Lower the Explorer until the tires just touch the ground.
• Use a torque wrench and 21mm socket to tighten lug nuts in a star pattern.
• Torque to 203 Nm (150 ft-lbs)

Step 12: Exit EPB service mode (if used)

• If you used an OBD2 scan tool with Ford EPB service mode (specialty), command EPB Service Mode OFF (or “Close/Apply” per tool wording).
• Cycle the EPB on/off once to confirm normal operation.

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✅ After Repair

• With the engine OFF, press the brake pedal slowly 8–10 times until it feels firm (this seats the pads).
• Check brake fluid level and top off with DOT 3 brake fluid if needed.
• Test at low speed first: confirm normal stopping and no grinding noises.
• Bed-in the pads: do 6–8 moderate stops from 50 km/h to 15 km/h, then drive 5–10 minutes to cool (avoid hard panic stops during bed-in).

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💰 DIY vs Shop Cost

Shop Cost: ₹12,000-₹25,000 (parts + labor)

DIY Cost: ₹6,000-₹16,000 (parts only)

You Save: ₹6,000-₹9,000 by doing it yourself!

Shop labor rates vary but typically run ₹800-₹2,000/hour. This repair takes a shop approximately 2-3 hours.

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